Footwear having a filled flex-frame midsole

ABSTRACT

An article of footwear may include a midsole having a flex-frame defining a plurality of cells. Some or all of the cells may be substantially filled with a foam material. The flex-frame may be made of a solid material having a greater stiffness than the foam material. The flex-frame may be unitary in construction.

CROSS-REFERENCES

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/099,136, filed on Dec. 31, 2014 and entitled“Footwear Having Filled Flex-Frame Midsoles.” The complete disclosure ofthe above application is hereby incorporated for reference for allpurposes.

INTRODUCTION

Work boots, athletic shoes, and other types of footwear may be designedand constructed from materials that make the footwear highly resistantto wear and tear. For example, the shoes may be designed to includethick outsoles and/or thick midsoles. Such features may be constructedfrom rubber and/or other protective materials to improve the durabilityof the shoes. However, known designs and materials may lead to shoeshaving an increased mass, a relatively low level of responsiveness,and/or a relatively low rate of energy return. Any or all of theseissues may contribute to discomfort and fatigue for a user.

SUMMARY

Footwear according to the present teachings overcomes the drawbacksdescribed above by incorporating a midsole that includes a flex-framehaving a plurality of spring-like cells. Some or all of the cells may besubstantially filled (e.g., with a high-rebound foam). Benefits of thisapproach may include lighter weight, higher responsiveness, and a highrate of energy return.

The present disclosure provides systems, apparatuses, and methodsrelating to an article of footwear comprising an upper; and a soleportion coupled to the upper and including an outsole and a midsole; themidsole including a resiliently-flexible kinematic frame having aplurality of cells, and a foam at least partially surrounding the frame;wherein the frame comprises a solid material having a greater stiffnessthan the foam.

In some embodiments, a sole for an article of footwear may include amidsole including a plurality of cells each defining an internal volumeand mechanically coupled to form a unitary resilient frame; and acompressible foam surrounding the plurality of cells and filling theinternal volume of at least one of the cells; wherein the resilientframe has a higher stiffness than the foam.

In some embodiments, an article of footwear may include an upper; and asole coupled to the upper, the sole including a plurality of moldedspring-like cells integrated into a single layer to form a flexiblyresilient kinematic frame, each cell extending at least partially acrossa width of the sole; wherein an interior volume of each cell issubstantially filled with a compressible foam material.

Features, functions, and advantages may be achieved independently invarious embodiments of the present disclosure, or may be combined in yetother embodiments, further details of which can be seen with referenceto the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of an illustrative article of footwearincluding a midsole having a flex-frame substantially filled with foam,in accordance with aspects of the present disclosure.

FIG. 2 is an isometric partial cutaway view of a portion of the midsoleof FIG. 1, with the foam partially removed to show the flex-frame.

FIG. 3 is a side elevation view of an illustrative article of footwearhaving a midsole similar to that shown in FIG. 1.

FIG. 4 is a side elevation view of an illustrative article of footwearhaving a flex-frame midsole substantially filled with foam, with theflex-frame midsole including reverse direction kinematic springs.

FIG. 5 is a side elevation view of an illustrative article of footwearincluding another example of a substantially filled flex-frame midsole.

FIG. 6 is a side elevation view of an illustrative article of footwearincluding a substantially filled flex-frame midsole having generallyevenly spaced kinematic springs.

FIG. 7 is a side elevation view of an illustrative article of footwearhaving a substantially filled flex-frame, wherein the flex-framecomprises a midsole and an outsole portion of the footwear.

FIG. 8 is a side elevation view of an illustrative article of footwearincluding a midsole having a substantially filled flex-frame with adiscontinuous upper portion.

FIG. 9 is a side elevation view of an illustrative article of footwearincluding a midsole having a substantially filled flex-frame withdiscontinuous upper and lower portions.

DESCRIPTION Overview

Various aspects and examples of footwear having filled flex-framemidsoles, as well as related methods, are described below andillustrated in the associated drawings. Unless otherwise specified, anarticle of footwear and/or its various components may, but are notrequired to, contain at least one of the structure, components,functionality, and/or variations described, illustrated, and/orincorporated herein. Furthermore, unless specifically excluded, theprocess steps, structures, components, functionalities, and/orvariations described, illustrated, and/or incorporated herein inconnection with the present teachings may be included in other similardevices and methods, including being interchangeable between disclosedembodiments. The following description of various examples is merelyillustrative in nature and is in no way intended to limit thedisclosure, its application, or uses. Additionally, the advantagesprovided by the examples and embodiments described below areillustrative in nature and not all examples and embodiments provide thesame advantages or the same degree of advantages.

In the following descriptions, various direction- or orientation-relatedterms, such as up, down, vertical, horizontal, width, height, and thelike are used when describing features and aspects of footwear. Unlessindicated otherwise, these terms are intended to be understood in thecontext of an article of footwear, the sole of which is supported on agenerally planar surface (e.g., a floor). The force of gravity isassumed to be generally normal to this support surface. Accordingly, inthis context, “down” is understood as the direction of the force ofgravity.

In general, an article of footwear, such as a boot or shoe, according tothe present teachings may include a midsole having a kinematicflex-frame co-molded with high-rebound foam (or other suitablehigh-rebound material). As used herein, the term “kinematic” refersgenerally to an assembly or device comprising a plurality of mechanicalelements capable of relative motion with respect to each other. Eachkinematic flex-frame, also referred to as a frame or framework, may bemolded as one piece of material having a plurality of cells or springportions formed by ribs or other suitable substructures. The flex-framemay be configured to bend and flex elastically as one unit, while alsobeing sufficiently stiff or rigid to support an expected load (e.g., theweight of a user) without collapsing. The flex-frame may be described asstructural, in that it may form a structural element of the sole. Theflex-frame may be of unitary construction, such that the individualcells or spring elements are attached to form a cohesive whole. In someexamples, this may be accomplished by forming or molding the flex-frameas a single piece of material. Weight and pressure may be effectivelytransferred throughout the flex-frame due to its shape, materialqualities, and/or its ability to bend and flex as a completecomposition.

Ribs or kinematic spring portions of the flex-frame may be shaped toprovide an elastic or spring-like return and motion with each step.Individual cells or spring portions may be compressed and/or expanded,depending on pressure points created by the distribution of weight ofthe user on different portions of the foot supported by the sole of thefootwear. In general, a kinematic frame may have a shape, a materialquality or qualities, and/or an ability to bend and flex as a completeunit (e.g., as described above), which enable the kinematic frame toeffectively transfer or distribute applied pressure throughout itscomposition. According to aspects of the present teachings, such akinematic frame may be supplemented and/or filled with foam or otherhigh-rebound and/or relatively light material, and incorporated into afootwear midsole. High rebound foam or other suitable material may fillor partially fill one or more open cells of the flex-frame to reinforcehigh-energy return qualities thereof. Such a midsole may be relativelylightweight and responsive, with a high rate of energy return ascompared to known midsoles.

The cells (also referred to as chambers) of the flex-frame may have anysuitable shape or combination of shapes. For example, cells may have agenerally polygonal cross-section, the section being taken along a linegenerally parallel to a long axis of the sole or footwear. Due to theextent and open-ended nature of the cells, these shapes may be visibleon the sides of the soles, as shown in the drawings. In some examples,the cells may have parallelogram-like shapes (e.g., as shown in FIGS. 1and 5), may have generally trapezoidal or slanted trapezoidal shapes(e.g., as shown in FIG. 4), may have substantial crescent-like shapes(e.g., as shown in FIG. 6), may have free-form or rounded shapes (e.g.,as shown in FIG. 7), and/or the like, or any combination of these. Insome embodiments, different individual cells may have different shapes,such as circular, triangular, rectangular, and/or any suitablecurvilinear and/or rectilinear shape(s). Regardless of the sectionalshape, each cell may form a chamber having an interior volume. Each ofthese chambers may extend width-wise across at least a portion of thesole of the footwear. Each of the chambers may be open at lateral endsand/or at other locations on the perimeter.

Additionally, the cells may be any suitable size or combination ofsizes. For example, one or more cells may have a larger vertical heightas compared to the height of one or more other cells. For example, oneor more cells disposed in toe and/or heel regions of the associatedfootwear may have larger height(s) than one or more cells disposed in acentral arch region of the associated footwear, which may provide forgreater energy transfer from relatively high impact regions.

In general, the resilient flex-frame may comprise a solid materialhaving a greater stiffness than the foam. In some embodiments, theflex-frame may be made of nylon. In some examples, the foam used to fillcells of the flex-frame may comprise ethylene-vinyl acetate (EVA) orother relatively high-rebound material or foam, such as polyurethane(PU) or thermoplastic polyurethane (TPU), or the like, and/or acombination of these. The high-rebound material (e.g., foam) may haveany material characteristic and/or property suitable for biasing theflex-frame toward a substantially non-compressed (e.g., expanded orrebounded) position. In some examples, the high-rebound material (e.g.,EVA and/or PU) may have a density in a range of about 0.8 to about 2.0pounds per cubic foot (PCF), and/or a durometer level (or hardness) in arange of about 45 to about 65 shore C. However, in some embodiments thehigh-rebound foam may have other characteristics, such as a suitabledensity and/or hardness outside of these respective ranges. The-highrebound foam may fill and cover the inside and outside of the kinematicframe. The kinematic frame may cross or span (e.g., extend across) theentire width of the sole of the footwear.

In some embodiments, co-molded supplemental foam may disperse the weighton the midsole, which may permit a thickness of the kinematic frame tobe optimized (e.g., reduced as compared to known sole flex-frames),while still providing responsiveness and a high rate of energy return.In some embodiments, the thickness may be tailored to a desired function(e.g., a selected responsiveness and/or energy return). Such anembodiment may provide a lightweight, responsive, and high rate ofenergy return midsole, as similarly described above.

In some embodiments, the flex-frame may be made of a molded plasticcomposition, such as one made of nylon or carbon fiber reinforcedpolymer (also referred to as carbon fiber). EVA or TPU (or other highrebound foam or material) may be directly injected or cemented inside atleast one cell defined by the flex-frame. One or more compression spaces(or zones) between adjacent cells may be hollow or partially hollow, ormay be filled with foam or other high-rebound material.

In some embodiments, a combination of a nylon flex-frame and moldedhigh-rebound foam (e.g., filling cells of the flex-frame and/orcompression zones) may provide improved cushioning (e.g., for a user'sfoot disposed inside an associated footwear upper) for increased periodsof time, without the associated material becoming packed down. In otherwords, midsoles in accordance with aspects of the present disclosure mayprevent significant loss of resiliency over time.

EXAMPLES, COMPONENTS, AND ALTERNATIVES

The following sections describe selected aspects of exemplary footwearhaving filled flex-frame midsoles, as well as related systems and/ormethods. The examples in these sections are intended for illustrationand should not be interpreted as limiting the entire scope of thepresent disclosure. Each section may include one or more distinctexamples, and/or contextual or related information, function, and/orstructure.

Illustrative Footwear Example 1

As shown in FIGS. 1-3, this section describes an illustrative article offootwear 100. Footwear 100 is an example of footwear having afoam-filled flex-frame, as described in the overview above. Accordingly,corresponding components and aspects may share substantially identicalcharacteristics as described above.

Footwear 100 may include an upper portion 104 and a sole portion 108.Upper portion 104 may include any suitable footwear upper configured toreceive a foot of a user and be selectively secured thereto (e.g., bylacing, hook-and-loop fasteners, and/or the like). Sole portion 108 maybe coupled (e.g., attached or affixed) to upper portion 104. Soleportion 108 may include any suitable sub-portions or layers, such as anoutsole (or outer sole layer) 112, a midsole (or midsole layer) 116, andan interface (or interface layer) 120. The outsole, the midsole, and/orthe interface may extend at least substantially along the entire lengthof footwear 100. Although sole portion 108 is shown to include adistinct outsole 112, midsole 116, and interface 120, sole portion 108may additionally, or alternatively, include any other suitableconfiguration of layer(s). For example, one or more of the sub-portionsor layers may be combined into a single structure. In some examples,sole portion 108 may exclude interface 120.

In this example, midsole 116 is coupled to upper portion 104 (e.g., viainterface 120, adhesive, sewing, bonding, welding, and/or othermechanisms). Outsole 112 may be disposed opposite upper portion 104relative to midsole 116. In other words, outsole 112 may be disposed on(or otherwise comprise) a bottom surface of sole portion 108. Theoutsole may include a plurality of projections, ridges, and/or recessesconfigured to improve traction, and/or to transfer kinetic energybetween the foot of the user and an external surface (e.g., a road,trail, or other surface) via midsole 116. Although the footwear of FIG.1 includes an outsole that wraps around at least a portion of the toe ofthe footwear, the footwear of the present disclosure may include anysuitable outsole. In some examples, footwear 100 may include an outsolethat does not wrap around the toe and/or that may wrap around at least aportion of the heel of the footwear.

Midsole 116 may be configured to store or absorb kinetic energy andreturn or transfer the stored energy back into the user's step. Forexample, midsole 116 may include a kinematic frame (also referred to asa flex-frame or framework) 124 substantially filled with a relativelyhigh-rebound material, such as foam 128. Components of midsole 116 maycomprise any suitable materials configured to minimize weight and/orimprove transfer of energy back to the user. For example, flex-frame 124may be made of nylon, carbon fiber reinforced polymer, or any othersuitable relatively light resilient material. Foam 128 may be made ofEVA, PU, or any other suitable high rebound material. In someembodiments, foam 128 may include a closed-cell foam, which may improvea rebound characteristic of midsole 116, an open-celled foam, which mayimprove a cushioning characteristic of midsole 116, and/or a combinationof closed-cell and open-cell foams.

A substantially resilient member 132 (e.g., made of nylon, carbon fiber,or any other suitable relatively light, resilient material) may formcontinuous flex-frame 124. Continuous flex-frame 124 may include aplurality of cells, such as cells 136A through 136H. Resilient member132 may form a generally continuous base member 140. Base member 140 mayextend along a length of footwear 100, e.g., along the entire length offootwear 100. Base member 140 may form a floor portion of each ofdiscrete cells 136A-136H. For example, base member 140 may form a floorportion 140A of cell 136A, a floor portion 140B of cell 136B, a floorportion 140C of cell 136C, and so on.

Resilient member 132 may further include or form a plurality of ribs orkinematic springs, a few of which are indicated respectively at 144,146, 148, 150, 152, and 154, and a plurality of interconnecting portions(also referred to as upper portions), three of which are indicatedrespectively at 156, 158, and 160. Pairs of ribs may form opposing sidewalls of the associated cell, and may be interconnected by an associatedinterconnecting portion (e.g., forming a ceiling portion of theassociated cell). For example, opposing ribs 144 and 146 may extend fromfloor portion 140B, and may form opposing side walls of cell 136B.Similarly, interconnecting portion 156 may extend between opposing ribs144 and 146 to form a ceiling portion of cell 136B opposite floorportion 140B.

Floor portion 140C, opposing ribs 148, 150, and upper portion 158 maydefine cell 136C (e.g., a perimeter thereof). As shown, the other cellsmay be similarly defined and/or formed. However, in some embodiments,such as the one shown here, cell 136H in a heel portion of midsole 116may have an open end at a rear of sole 108. For example, cell 136H mayhave only one defining generally vertical side wall or kinematic spring,rather than two opposing kinematic springs. Similarly, in someembodiments, a cell in a toe portion of midsole 116 (not shown) may alsohave an open end.

As mentioned above, foam 128 may substantially fill flex-frame 124. Morespecifically, foam 128 may substantially, generally, or completely fillsome or all of cells 136A-136H. Compression zones 162A-162G may berespectively disposed between adjacent cells in midsole 116. Forexample, side walls of adjacent cells may be spaced apart to define agap, space, or compression zone therebetween. As shown in FIG. 1, thesecompression zones may be tapered, such that the side walls of adjacentcells are closer together near the bottom of the compression zone thanthey are near the top. For example, a compression zone may have a “V”shaped cross section when viewed from a lateral side of the footwear.

One or more of the compression zones may be filled with foam 128 (orother suitable high-rebound material). As shown, each of thesecompression zones may be filled with foam 128. However, in someembodiments, one or more of these compression zones may be unfilled orhollow. The inclusion of one or more hollow compression zones may reducea weight of footwear 100. Conversely, one or more filled compressionzones may increase energy absorption and return. In some embodiments,such as the one shown in FIG. 1, foam 128 (or another high-reboundmaterial) may also form interface layer 120, which may be coupled toand/or co-molded with the foam filling the compression zones anddisposed adjacent upper portion 104. In some embodiments, interfacelayer 120 may be coupled to and/or co-molded with upper portions offlex-frame 124.

More specifically, as shown in FIG. 2, each of cells 136A-136H may have,substantially enclose, or generally surround a respective volume. Forexample, cell 136B may have a volume V1, and cell 136C may have a volumeV2. A majority of volumes V1 and V2, as well as the other volumessubstantially enclosed by the other cells, may be generally filled withfoam 128 (or other suitable high-rebound material). In some embodiments,void spaces may be included within one or more of the cells. Forexample, one or more air pockets may be formed in one or more of thecells.

In FIG. 2, it should be noted that a portion of foam 128 has beenremoved to depict an exemplary extent of flex-frame 124 and foam 128.For example, flex-frame 124 may extend across an entire width W1 offootwear 100. In some embodiments, flex-frame 124 may extend across lessthan width W1. For example, in some embodiments, flex-frame 124 (and/orone or more additional similar structures) may extend across a centralportion of width W1, and/or one or more lateral side portions of widthW1.

FIG. 3 shows a more detailed view of footwear 100. As shown, upperportion 104 of footwear 100 may include laces 164, or any other suitabledevice or apparatus for securing a user's foot within upper portion 104.Further, flex-frame 124 may include a rear portion 166. As shown, rearportion 166 may wrap around a rear end of interface layer 120 and extendtoward upper portion 104. Such a configuration may improve energytransfer to the user and/or improve an attachment of flex-frame 124 tointerface 120.

In an exemplary operation, compression of midsole 116 may result inflex-frame 124 flexing downward and/or laterally. For example, thetoe-wardly angled cells of flex-frame 124 depicted in FIG. 3 may flexdownward and toe-ward (i.e., forward) when midsole 116 is compressed.Such a flexing motion may load one or more of the ribs of flex-frame 124(e.g., with a restorative force). Such flexing may also decrease one ormore volumes of respective cells 136A-136H, which may load (e.g.,compress) foam 128 in the associated cells and/or compression zones.Such absorption of force over a corresponding distance (or distances)may store associated energy in midsole 116 (e.g., in flex-frame 124and/or foam 128), which may then be returned to the user, for example,as these loads are released as midsole 116 returns, expands, or reboundsto the position depicted in FIG. 3.

Illustrative Footwear Example 2

As shown in FIG. 4, this section describes another illustrative articleof footwear 400. Footwear 400 is an example of footwear having afoam-filled flex-frame, as described in the overview above. Accordingly,corresponding components and aspects may share substantially identicalcharacteristics as described above. Where aspects of footwear 400 aresimilar to those of footwear 100, corresponding features are labeledwith versions of the same reference numbers, but starting with “4”rather than “1.” For example, footwear 400 includes an upper portion 404coupled to a sole portion 408 having an outsole 412, a midsole 416, andan interface portion 420, all generally as described above with respectto elements 104, 108, 112, 116, and 120.

Midsole 416 includes a filled flex-frame 424, which may be similar instructure and/or function to flex-frame 124. Flex-frame 424 may define aplurality of cells, such as cells 436A-436F, which may be substantiallyfilled with a foam 428 (or other suitable high rebound material). One ormore compression zones, such as compression zones 462A-462E, betweenadjacent cells may similarly be filled with a high rebound material(e.g., foam 428).

In contrast to the generally continuous base member 140 of flex-frame124, flex-frame 424 includes a resilient, generally continuous ceilingmember 440. In other words, the cells of flex-frame 424 depend downwardfrom the continuous member of the frame, while the cells of flex-frame124 extend upward. Ceiling member 416 may form and/or define upperportions of one or more of cells 436A-436F, as well as upper portions ofassociated compression zones therebetween. Lower portions 440A-440F offlex-frame 424 may form respective bases of cells 436A-436F. Each ofthese lower portions may be coupled (e.g., bonded, adhered, and/or thelike) to outsole 412. Such a configuration may provide for increasedenergy return of footwear 400.

Illustrative Footwear Example 3

As shown in FIG. 5, this section describes another illustrative articleof footwear 500. Footwear 500 is an example of footwear having afoam-filled flex-frame, as described in the overview above. Accordingly,corresponding components and aspects may share substantially identicalcharacteristics as described above. Where aspects of footwear 500 aresimilar to those of footwear 100, corresponding features are labeledwith versions of the same reference numbers, but starting with “5”rather than “1.” For example, footwear 500 includes an upper portion 504coupled to a sole portion 508 having an outsole 512, a midsole 516, andan interface portion 520, all generally as described above with respectto elements 104, 108, 112, 116, and 120.

Midsole 516 includes a filled flex-frame 524, which may be similar instructure and/or function to flex-frame 124. Flex-frame 524 may define aplurality of cells, such as cells 536A-536K, which may each besubstantially filled with a foam 528 (or other suitable high-reboundmaterial). As shown, a continuous upper resilient member 532A and lowerresilient member 532B of flex-frame 524 may respectively form a ceilingand a base portion of cells 536A-536K. In contrast to flex-frame 124,which included a base member with cells extending upward, and flex-frame424, which included a ceiling member with cells extending downward,flex-frame 524 includes both a ceiling and a base member sandwiching thecells.

Ribs of flex-frame 524, two of which are indicated at 544 and 546, maypartition a generally enclosed volume between portions 532A and 532Binto cells 536A-536K. As shown in FIG. 5, the ribs of flex-frame 524 maybe angled heelward (e.g., toward the rear of the footwear) from bottomto top. In other words, the bottom of one (or all) of the ribs may befarther forward than the top of the same rib. In some examples, an angleθ1 formed between a rib and lower member 532B may be about 105 degreesto about 175 degrees, or any other suitable angle. For example, forheelwardly projecting ribs, as shown in FIG. 5, angle θ1 may be in arange of about 115 degrees to about 175 degrees. For toewardlyprojecting ribs, such as those shown in FIGS. 1-4, a corresponding anglemay be in a range of about 15 degrees to about 65 degrees. One or moreof the ribs may be substantially concave on an upward-facing surface.Such a configuration (or one or more aspects thereof) may result in amore toe-ward release of energy from midsole 516 to the user.

Illustrative Footwear Example 4

As shown in FIG. 6, this section describes another illustrative articleof footwear 600. Footwear 600 is an example of footwear having afoam-filled flex-frame, as described in the overview above. Accordingly,corresponding components and aspects may share substantially identicalcharacteristics as described above. Where aspects of footwear 600 aresimilar to those of footwear 100, corresponding features are labeledwith versions of the same reference numbers, but starting with “6”rather than “1.” For example, footwear 600 includes an upper portion 604coupled to a sole portion 608 having an outsole 612, a midsole 616, andan interface portion 620, all generally as described above with respectto elements 104, 108, 112, 116, and 120.

Midsole 616 includes a filled flex-frame 624, which may be similar instructure and/or function to flex-frame 124 (and others describedabove). Flex-frame 624 may define a plurality of cells, such as cells636A-636D (among others). Cells of flex-frame 624 may be substantiallyfilled with a foam 628 (or other suitable high-rebound material).

Flex-frame 624 may include a plurality of ribs (or kinematic springs), afew of which are indicated at 644, 646, and 648. As shown, these ribsmay be generally distributed (e.g., evenly spaced) across a length ofmidsole 616. The ribs may each have a reduced thickness and/or height,as compared to ribs of footwear 100, 400, or 500.

Similar to flex-frame 524, flex-frame 624 may include continuous upperand lower resilient members 632A and 632B forming a respective ceilingand base of the cells of flex-frame 624. In some embodiments (e.g., asshown in FIGS. 8 and 9), one or both of portions 632A, 632B may bediscontinuous (e.g., having gaps between adjacent ribs). For example,one or more compression spaces or zones, similar to those describedabove, may be formed between adjacent cells.

In some examples, such as the one depicted in FIG. 6, one or more of theribs may be generally, substantially, or continually concave in atoeward or forward direction. For example, one or more of the ribs maybe radiused between upper and lower members 632A and 632B, such that agreater volume of an associated cell may be disposed in a heelwardportion of the cell than in a toeward portion of the cell. In someexamples, one or more of the ribs may instead be generally concave in aheelward or rear direction, and/or generally radiused such that agreater volume of an associated cell may be disposed in a toewardportion of the cell than in a heelward portion of the cell. In someexamples, such curvature (or various combinations thereof) of one ormore of the ribs may be configured to improve energy rebound of footwear600, improve an associated weight distribution of the user provided byfootwear 600 to an external surface, and/or improve a cushioningcharacteristic of footwear 600.

Illustrative Footwear Example 5

As shown in FIG. 7, this section describes another illustrative articleof footwear 700. Footwear 700 is an example of footwear having afoam-filled flex-frame, as described in the overview above. Accordingly,corresponding components and aspects may share substantially identicalcharacteristics as described above. Where aspects of footwear 700 aresimilar to those of footwear 100, corresponding features are labeledwith versions of the same reference numbers, but starting with “7”rather than “1.” For example, footwear 700 includes an upper portion 704coupled to a sole portion 708 having an outsole 712, a midsole 716, andan interface portion 720, all generally as described above with respectto elements 104, 108, 112, 116, and 120.

Midsole 716 includes a filled flex-frame 724, which may be similar instructure and/or function to flex-frame 124 (and others describedabove). Flex-frame 724 may define a plurality of cells, such as cells736A-736D (among others).

In contrast to flex-frames 124, 424, 524, and 624 described above, thecells of flex-frame 724 may be formed between a substantially continuousupper/ceiling member 732 above and outsole 712 below. In other words,outsole 712 is integrated with flex-frame 724. Said another way, a lowersubstantially continuous member of flex-frame 724 may form outsole 712.

Flex-frame 724 may further include a plurality of generally verticalribs, a few of which are indicated at 744, 746, and 748. The ribs offlex-frame 724, in combination with upper and lower portions 732 and712, may define the plurality of cells within flex-frame 724. Byintegrating outsole 712 into flex-frame 724, a more organic or otherwisegenerally pleasing visual appearance may be achieved. Further, suchintegration may improve a structural integrity of footwear 700, and/orreduce a weight of the sole.

While the article of footwear is depicted as a work boot in FIGS. 1-7,other types of footwear or shoes (e.g., sandals, athletic shoes, dressshoes, casual shoes, dance shoes, and orthopedic shoes) may include oneor more of the structures described herein, such as a substantially foamfilled flex-frame.

Illustrative Footwear Example 6

As shown in FIG. 8, this section describes another illustrative articleof footwear 800. Footwear 800 is an example of footwear having afoam-filled flex-frame, as described in the overview above. Accordingly,corresponding components and aspects may share substantially identicalcharacteristics as described above. Where aspects of footwear 800 aresimilar to those of footwear 100, corresponding features are labeledwith versions of the same reference numbers, but starting with “8”rather than “1.” For example, footwear 800 includes an upper portion 804coupled to a sole portion 808 having an outsole 812, a midsole 816, andan interface portion 820, all generally as described above with respectto elements 104, 108, 112, 116, and 120.

Midsole 816 includes a filled flex-frame 824, which may be similar instructure and/or function to flex-frame 124 (and others describedabove). Flex-frame 824 may define a plurality of cells, such as cells836A-836G (among others). The cells of flex-frame 824 may besubstantially filled with a foam 828 (or other suitable high-reboundmaterial). As shown, one or more of the cells of flex-frame 824 may be“open.” For example, an entire perimeter of the cell may not be enclosedby the flex-frame. For example, a cell may be defined as an areasubstantially surrounded by (and/or enclosed by) an associated portionof flex-frame 824. As shown, backward-“C” shaped openings of one or moreof the cells of flex-frame 824 may have open mouths facing in an upwardand/or toeward (i.e., forward) direction. As shown in FIG. 8, thisarrangement may also be described as having upside-down “L”-shaped ribs.Alternatively or additionally, one or more of these backward-“C” shapedopenings may face in a downward and/or heelward (i.e., rearward)direction.

As described further above with reference to FIG. 6, an upper and/orlower member of the flex-frame may be discontinuous between adjacentcells. Such discontinuities may be configured to provide a desired levelof cushioning and/or energy rebound. For example, as shown in FIG. 8,upper portion 832A of flex-frame 824 is discontinuous between adjacentcells 836E and 836F (e.g., resulting in those cells being open). Such adiscontinuous upper portion 832A may permit foam 828 to be continuous inmidsole 816 (and/or throughout midsole 816 and into interface layer820).

As also shown, flex-frame 824 includes a substantially continuous lowerportion 832B. Alternatively and/or additionally, lower portion 832B mayinclude one or more discontinuities, e.g., in a manner similar to upperportion 832A.

Illustrative Footwear Example 7

As shown in FIG. 9, this section describes another illustrative articleof footwear 900. Footwear 900 is an example of footwear having afoam-filled flex-frame, as described in the overview above. Accordingly,corresponding components and aspects may share substantially identicalcharacteristics as described above. Where aspects of footwear 900 aresimilar to those of footwear 100, corresponding features are labeledwith versions of the same reference numbers, but starting with “9”rather than “1.” For example, footwear 900 includes an upper portion 904coupled to a sole portion 908 having an outsole 912, a midsole 916, andan interface portion 920, all generally as described above with respectto elements 104, 108, 112, 116, and 120.

Midsole 916 includes a filled flex-frame 924, which may be similar instructure and/or function to flex-frame 124 (and others describedabove). Flex-frame 924 may define a plurality of cells, such as cells936A-936E. The cells of flex-frame 924 may be substantially filled witha foam 928 (or other suitable high rebound material).

As shown, one or more of these cells of flex-frame 924 may be of “open”construction, in a manner similar to those of flex-frame 824. Forexample, flex-frame 924 may include a discontinuous upper portion 932Aand/or a discontinuous lower portion 932B. In the example shown in FIG.9, portions 932A and 932B are both discontinuous resulting in flex-frame924 comprising a plurality of discrete sections or disconnected parts.As shown FIG. 9, these discrete sections may have substantially “V”-and/or “W”-shaped section profiles, with the “W”-shaped section beingdisposed in an arch (or central) region of midsole 916. Alternatively,one or more “W”-shaped sections may be disposed in a toe and/or heelregion of midsole 916. One or more “V”-shaped sections may be disposedin an arch region of midsole 916. In some embodiments, the flex-framemay include sections (e.g., discrete or continuous) having othercross-sectional profiles, such as “Z” shapes, “T” shapes, “I” shapes, orfree form shapes.

As indicated, cells 936A, 936B, 936D, and 936E may be respectivelydefined between opposing portions of adjacent discrete sections offlex-frame 924, and/or between discontinuous upper portion 932A andoutsole 912. Cell 936C may be defined between a central portion of the“W”-shaped discrete section of flex-frame 924 and outsole 912. Such aconfiguration may permit a majority of foam 928 to be continuous inmidsole 916 (and/or throughout a majority of midsole 916 and extendingfrom interface layer 920 to outsole 912).

Illustrative Method of Use

The foot of a user may be secured in an article of footwear inaccordance with aspects of the present disclosure. The footwear mayinclude a sole having a substantially filled flex-frame. For example,the flex-frame may be substantially filled by foam, such as foam 128, oranother high-rebound material. The flex-frame may comprise a midsoleand/or a midsole/outsole portion of the footwear. The sole may beattached to an upper of the footwear. Securing the foot in the footwearmay include the user substantially securing the foot in the upper. Forexample, the user may dispose their foot in the upper, and tighten (orotherwise at least temporarily secure the upper to their foot), forexample via operation of laces, straps, or other suitable tighteningdevice, which may be included (or coupled to) the upper of the footwear.

The flex-frame may then be substantially compressed, such as when theuser is walking. For example, the user may substantially compress theflex-frame by applying pressure to an external surface with their footvia the flex-frame. The flex-frame (and/or the material substantiallyfilling the flex-frame, such as foam 128 or another suitablehigh-rebound material) may absorb energy transferred to the sole viacompression thereof.

Substantial decompression of the flex-frame may then be performed. Forexample, the user may at least partially remove pressure from theexternal surface via the flex-frame. Such at least partial removal ofpressure (or force) may permit the flex-frame and/or the materialsubstantially filling the flex-frame (e.g., foam 128) to substantiallytransfer the absorbed energy to the user. Such a transfer (or return) ofenergy may improve a responsiveness of the footwear, a cushioning effectimparted to the user's foot by the footwear, and/or a velocity at whichthe user may travel, among other characteristics. In some examples,decompression of the flex-frame may be aided by expansion of thepreviously-compressed foam filling.

Additional Examples and Features

This section describes aspects and features of footwear having a filledflex-frame midsole, presented without limitation as a series ofparagraphs, some or all of which may be alphanumerically designated forclarity and efficiency. Each of these paragraphs can be combined withone or more other paragraphs, and/or with disclosure from elsewhere inthis application, including the materials incorporated by reference inthe Cross-References, in any suitable manner. Some of the paragraphsbelow expressly refer to and further limit other paragraphs, providingwithout limitation examples of some of the suitable combinations.

A0. An article of footwear comprising:

an upper; and

a sole portion coupled to the upper and including an outsole and amidsole;

the midsole including a resiliently-flexible kinematic frame having aplurality of cells, and a foam at least partially surrounding the frame;

wherein the frame comprises a solid material having a greater stiffnessthan the foam.

A1. The article of footwear of A0, wherein the solid material of theframe comprises nylon.

A2. The article of footwear of A0, wherein the foam comprisesethylene-vinyl acetate.

A3. The article of footwear of A0, wherein the foam substantially fillsan interior of one or more of the cells.

A4. The article of footwear of A0, wherein adjacent cells of the frameare spaced apart, defining a respective compression zone there between,each compression zone being substantially filled with the foam.

A5. The article of footwear of A0, wherein the frame comprises at leastone continuous member running along a length of the sole and defining arespective perimeter portion of each of the cells.

A6. The article of footwear of A5, wherein the at least one continuousmember forms a respective lower portion of each of the cells.

A7. The article of footwear of A5, wherein the at least one continuousmember comprises an upper continuous member and a lower continuousmember, and the plurality of cells are formed between the upper andlower continuous members.

A8. The article of footwear of A7, wherein the lower continuous membercomprises the outsole.

B0. A sole for an article of footwear, the sole comprising:

a midsole including a plurality of cells each defining an internalvolume and mechanically coupled to form a unitary resilient frame; and

a compressible foam surrounding the plurality of cells and filling theinternal volume of at least one of the cells;

wherein the resilient frame has a higher stiffness than the foam.

B1. The sole of B0, wherein the frame has sufficient stiffness tosupport an expected user without collapsing.

B2. The sole of B0, wherein the frame comprises a thermoplasticmaterial.

B3. The sole of B2, wherein the thermoplastic material is nylon.

B4. The sole of B0, wherein the unitary frame is a single, molded piece.

B5. The sole of B4, wherein the foam is co-molded with the frame.

B6. The sole of B0, further comprising an outsole coupled to themidsole.

B7. The sole of B0, wherein the frame comprises at least one lengthwisecontinuous member joining the plurality of cells.

B8. The sole of B0, wherein adjacent cells are spaced apart along alength of the sole, such that a respective gap is formed betweenadjacent cells.

B9. The sole of B8, wherein each respective gap between adjacent cellsis filled with the foam.

B10. The sole of B0, wherein the plurality of cells are arranged in asingle layer of side-by-side cells.

C0. An article of footwear comprising:

an upper; and

a sole coupled to the upper, the sole including a plurality of moldedspring-like cells integrated into a single layer to form a flexiblyresilient kinematic frame, each cell extending at least partially acrossa width of the sole;

wherein an interior volume of each cell is substantially filled with acompressible foam material.

C1. The article of footwear of C0, wherein each cell has a polygonalcross section taken along a long axis of the sole.

C2. The article of footwear of C0, wherein the layer of cells areconnected by at least one common lengthwise member.

C3. The article of footwear of C2, wherein the at least one commonlengthwise member comprises an upper member and the cells dependdownward from the upper member.

C4. The article of footwear of C2, wherein the at least one commonlengthwise member comprises a lower member and the cells extend upwardfrom the lower member.

C5. The article of footwear of C2, wherein the at least one commonlengthwise member comprises an upper member and a lower member, and thecells are formed between the upper and lower members.

C6. The article of footwear of C0, wherein each of the cells is angledforward toward a toe of the footwear, such that an upper portion of eachcell is farther forward than a lower portion of the same cell.

C7. The article of footwear of C0, wherein the frame further comprisesat least one gap between adjacent cells.

C8. The article of footwear of C7, wherein the at least one gap issubstantially filled with the foam.

C9. The article of footwear of C0, wherein a lower portion of the framecomprises an outsole.

D0. A sole for footwear, the sole comprising:

a flex-frame defining a plurality of cells; and

foam substantially filling one or more of the cells.

D1. The sole of paragraph D0, wherein the foam generally fills each cellof the plurality of cells.

D2. The sole of paragraph D1, wherein the foam completely fills one ormore of the cells.

D3. The sole of paragraph D2, wherein the foam completely fills eachcell of the plurality of cells.

D4. The sole of paragraph D0, wherein adjacent cells are spaced apartdefining a compression zone therebetween, the compression zone beinggenerally filled with foam.

D5. The sole of paragraph D0, wherein a lower portion of the flex-frameforms an outsole portion of the sole configured to engage an externalsurface.

E0. Footwear comprising:

an upper for receiving a foot of a user; and

a sole including a midsole and an outsole, the midsole being coupled tothe upper, the outsole being disposed opposite the upper relative to themidsole, the outsole being configured to transfer kinetic energy betweenthe foot of the user and an external surface via the midsole, themidsole including a substantially flexible framework defining aplurality of cells, one or more of the cells being substantially filledwith foam.

E1. The footwear of paragraph E0, wherein each of the cells has arespective volume, a majority of the volume of each cell being filledwith foam.

E2. The footwear of paragraph E1, wherein the entire volume of each cellis generally filled with foam.

E3. The footwear of paragraph E2, wherein the entire volume of each cellin a vertical section of the midsole taken along an elongate axis of themidsole is completely filled with foam.

E4. The footwear of paragraph E0, wherein the foam includes closed-cellfoam.

E5. The footwear of paragraph E0, wherein the foam includes open-cellfoam.

F0. Footwear comprising:

an upper; and

a sole including a substantially resilient member forming a continuousflex-frame that defines a plurality of cells, at least one of the cellsbeing substantially filled with foam.

F1. The footwear of paragraph F0, wherein adjacent cells are spacedapart to define a compression zone there between, the compression zonebeing generally filled with foam.

F2. The footwear of paragraph F1, wherein the compression zone and theflex-frame are disposed between the upper and an outsole portion of thefootwear.

F3. The footwear of paragraph F2, wherein the compression zone isadjacent the upper.

F4. The footwear of paragraph F2, wherein the compression zone isadjacent the outsole portion of the sole.

F5. The footwear of paragraph F0, wherein the flex-frame and theplurality of cells extend across an entire width of the footwear.

F6. The footwear of paragraph F0, wherein the flex-frame is made ofnylon, and the foam is made of ethylene-vinyl acetate (EVA).

G0. A method comprising:

substantially securing a foot of a user in an article of footwear, thefootwear including a sole having a substantially foam-filled flex-frame;

substantially compressing the flex-frame, thereby absorbing energytherein; and

substantially decompressing the flex-frame, thereby transferring theabsorbed energy to the user.

G1. The method of G0, wherein decompression of the flex-frame is aidedby expansion of the foam.

CONCLUSION

The disclosure set forth above may encompass multiple distinct exampleswith independent utility. Although each of these has been disclosed inits preferred form(s), the specific embodiments thereof as disclosed andillustrated herein are not to be considered in a limiting sense, becausenumerous variations are possible. To the extent that section headingsare used within this disclosure, such headings are for organizationalpurposes only. The subject matter of the invention(s) includes all noveland nonobvious combinations and subcombinations of the various elements,features, functions, and/or properties disclosed herein. The followingclaims particularly point out certain combinations and subcombinationsregarded as novel and nonobvious. Other combinations and subcombinationsof features, functions, elements, and/or properties may be claimed inapplications claiming priority from this or a related application. Suchclaims, whether broader, narrower, equal, or different in scope to theoriginal claims, also are regarded as included within the subject matterof the present disclosure.

What is claimed is:
 1. An article of footwear comprising: an upper; anda sole portion coupled to the upper and including an outsole and amidsole; the midsole including a resiliently-flexible kinematic framehaving a plurality of cells, and a foam at least partially surroundingthe frame; wherein the frame comprises a solid material having a greaterstiffness than the foam.
 2. The article of footwear of claim 1, whereinthe solid material of the frame comprises nylon.
 3. The article offootwear of claim 1, wherein the foam comprises ethylene-vinyl acetate.4. The article of footwear of claim 1, wherein the foam substantiallyfills an interior of one or more of the cells.
 5. The article offootwear of claim 1, wherein the frame comprises at least one continuousmember running along a length of the sole and defining a respectiveperimeter portion of each of the cells.
 6. The article of footwear ofclaim 5, wherein the at least one continuous member forms a respectivelower portion of each of the cells.
 7. The article of footwear of claim5, wherein the at least one continuous member comprises an uppercontinuous member and a lower continuous member, and the plurality ofcells are formed between the upper and lower continuous members.
 8. Asole for an article of footwear, the sole comprising: a midsoleincluding a plurality of cells each defining an internal volume andmechanically coupled to form a unitary resilient frame; and acompressible foam surrounding the plurality of cells and filling theinternal volume of at least one of the cells; wherein the resilientframe has a higher stiffness than the foam.
 9. The sole of claim 8,wherein the frame has sufficient stiffness to support an expected userwithout collapsing.
 10. The sole of claim 8, wherein the frame comprisesa thermoplastic material.
 11. The sole of claim 8, wherein the unitaryframe is a single, molded piece.
 12. The sole of claim 8, wherein theframe comprises at least one lengthwise continuous member joining theplurality of cells.
 13. The sole of claim 8, wherein adjacent cells arespaced apart along a length of the sole, such that a respective gap isformed between adjacent cells.
 14. The sole of claim 8, wherein theplurality of cells are arranged in a single layer of side-by-side cells.15. An article of footwear comprising: an upper; and a sole coupled tothe upper, the sole including a plurality of molded spring-like cellsintegrated into a single layer to form a flexibly resilient kinematicframe, each cell extending at least partially across a width of thesole; wherein an interior volume of each cell is substantially filledwith a compressible foam material.
 16. The article of footwear of claim15, wherein a cross section of each cell taken parallel to a long axisof the sole is generally polygonal.
 17. The article of footwear of claim15, wherein the layer of cells are connected by at least one commonlengthwise member.
 18. The article of footwear of claim 17, wherein theat least one common lengthwise member comprises an upper member and alower member, and the cells are formed between the upper and lowermembers.
 19. The article of footwear of claim 15, wherein each of thecells is angled forward toward a toe of the footwear, such that an upperportion of each cell is farther forward than a lower portion of the samecell.
 20. The article of footwear of claim 15, wherein a lower portionof the frame comprises an outsole.